Brake Caliper - Front

This procedure covers removal and replacement of the front brake caliper on a 2023 Chevrolet Bolt EUV, including brake fluid bleeding and torque specifications.

Warnings

Tools required

Parts

• Front brake caliper assembly × 1 — Use OEM specification
• Brake banjo bolt copper washers × 2 — Two washers per banjo bolt
• Brake fluid × 1 — ACDelco DOT 4

Fluids

• ACDelco DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level, solid surface and engage parking brake firmly
2. Chock rear wheels securely to prevent rolling
3. Loosen front wheel lug nuts 1/4 turn while vehicle is on ground
4. Lift front of vehicle with floor jack at manufacturer-specified jacking points
5. Support vehicle securely on jack stands rated for vehicle weight (at least 2 tons each)
6. Remove front wheel completely
7. Open hood and locate brake fluid reservoir. Check fluid level and mark current level
8. Place a catch pan under the brake caliper area to catch fluid spillage
9. Have fresh DOT 4 brake fluid ready in sealed container

Procedure

1. 1

   Secure brake hose and prepare for removal
   Clean the area around the brake hose banjo bolt connection at the caliper to prevent contamination. Have a shop towel ready to catch brake fluid. Do not depress the brake pedal once the caliper is disconnected or the piston will extend.
2. 2

   Disconnect brake hose from caliper
   Using a 10mm brake line wrench, loosen and remove the brake hose banjo bolt from the caliper. Brake fluid will drain out - catch it in your pan. Remove and discard both copper sealing washers from the banjo bolt (one on each side). Immediately plug the brake hose opening with a rubber cap or wrap in plastic to minimize fluid loss and prevent contamination. Do not allow the brake hose to hang unsupported - secure it with wire or a bungee cord to prevent stress on the brake line.
3. 3

   Remove caliper mounting bolts
   Locate the two caliper mounting bolts on the rear of the caliper (these attach the caliper to the bracket). Using an 18mm socket and ratchet, remove both caliper mounting bolts completely. Support the caliper with your hand as you remove the second bolt to prevent it from falling. The caliper should now be free from the bracket and rotor.
4. 4

   Remove old caliper
   Carefully lift the old caliper away from the rotor and bracket assembly. Inspect the caliper bracket, rotor, and brake pads (if not being replaced) for unusual wear, damage, or contamination. Remove the brake pads from the bracket if they are staying in place, or discard if replacing. Clean the caliper bracket slides and contact points with brake cleaner and a wire brush.
5. 5

   Prepare new caliper for installation
   Remove the new caliper from its packaging. Verify that the caliper piston is fully retracted - if not, use a C-clamp or caliper piston tool to carefully compress it fully into the caliper bore. Check that all bleeder screws are closed (turned clockwise). Remove any shipping plugs from the brake hose port. Apply a light coat of fresh brake fluid to the piston dust boot.
6. 6

   Install brake pads and position new caliper
   If using existing pads, reinstall them in the caliper bracket in their original orientation. If installing new pads, apply anti-squeal compound to the backing plates as directed. Position the new caliper over the rotor and pads, aligning the mounting bolt holes with the bracket.
7. 7

   Install and torque caliper mounting bolts
   Apply medium-strength thread locker to the threads of both caliper mounting bolts. Insert both bolts and hand-tighten them. Using a torque wrench, tighten both mounting bolts to exactly 102 Nm (75 lb-ft) in a cross pattern. Verify the caliper is seated flush against the bracket and moves freely on the slides.
8. 8

   Reconnect brake hose with new washers
   Install NEW copper sealing washers onto the brake hose banjo bolt - one washer goes on each side of the banjo fitting. Remove the plug or covering from the brake hose. Align the banjo fitting with the caliper inlet port and insert the banjo bolt through the fitting and into the caliper. Hand-tighten the banjo bolt, then use a brake line wrench and torque wrench to tighten to exactly 41 Nm (30 lb-ft). Do not overtighten as this can damage the fitting or cause leaks.
   ⚠Using old copper washers will result in brake fluid leaks. Always use new washers.
9. 9

   Bleed brake caliper
   Top off the brake fluid reservoir with fresh DOT 4 brake fluid to the MAX line. Attach a clear bleeder hose to the caliper bleeder screw and place the other end in a container with a small amount of brake fluid. Have an assistant pump the brake pedal 3-4 times and hold pressure. Open the bleeder screw 1/4 turn using a 10mm wrench - fluid and air will flow out. When flow stops, close the bleeder screw before your assistant releases the pedal. Repeat this process until no air bubbles appear in the fluid (typically 4-6 cycles). Continuously monitor and refill the reservoir to prevent it from running dry.
   ⚠️Never let the brake fluid reservoir run empty during bleeding. This will introduce air into the ABS system requiring dealer-level scan tool to bleed.
   Torque spec

   Bleeder Screw10 Nm (7 lb-ft)
10. 10

    Final bleeder screw torque
    Once bleeding is complete and no air bubbles are visible, have your assistant hold brake pedal pressure one final time. Close the bleeder screw and torque to exactly 10 Nm (7 lb-ft) using a torque wrench. Remove the bleeder hose. Wipe away any spilled brake fluid with a clean shop towel.
    ⚠The bleeder screw is brass and easily damaged. Do not overtighten beyond 10 Nm or it will strip.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
11. 11

    Inspect for leaks and finalize
    Carefully inspect all connections (banjo bolt and bleeder screw) for any signs of brake fluid leakage. Wipe the area clean and watch for several seconds. If any leaks are observed, immediately correct them before proceeding. Top off the brake fluid reservoir to the MAX line. Clean any brake fluid residue from the caliper, rotor, and surrounding areas with brake cleaner.
12. 12

    Reinstall wheel and lower vehicle
    Mount the wheel onto the hub, ensuring it seats properly against the hub face. Install all lug nuts and hand-tighten in a star pattern. Lower the vehicle until the tire just contacts the ground but most weight is still on the jack stands. Using a torque wrench, tighten lug nuts to exactly 136 Nm (100 lb-ft) in a star pattern. Fully lower the vehicle and remove jack stands. Perform a final torque check on lug nuts.

Reassembly

1. Ensure brake fluid reservoir is filled to MAX line with fresh DOT 4 fluid
2. All caliper mounting bolts, banjo bolt, and bleeder screw must be torqued to exact specifications
3. Verify no brake fluid leaks at any connection points
4. Wheel lug nuts must be torqued in proper star pattern to prevent rotor warping

Verification

• With engine off, pump brake pedal several times - it should become firm and hold pressure. A spongy pedal indicates air in the system requiring additional bleeding
• Start the vehicle and verify the brake warning light is not illuminated on the dashboard
• Check brake fluid reservoir level - it should be at MAX line with no visible leaks
• Perform a low-speed brake test in a safe area (under 10 mph) to verify the brake engages smoothly without pulling to one side
• Inspect all connections one final time for any signs of fluid seepage after test
• Perform a more aggressive brake test from 25-30 mph in a safe area, verifying straight-line stops with good pedal feel
• If brake pedal feels soft, travels too far, or vehicle pulls to one side, DO NOT DRIVE and repeat bleeding procedure or seek professional service
• Monitor brake fluid level over the next few days and check for leaks after first 50 miles of driving

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